Product Info - 3D Automazione3dautomazione.com/Product info_E_2012.pdf · Product Info Innovative automation solutions for textile fi nishing

Product InfoInnovative automation solutions for textile fi nishing

www.setex-germany.com

2

Many textile machine manufacturers around the world are fi nding their ways to reduce carbon emission and the

use of energy. The complexity in textile production is growing constantly. SECOM controls are adding accessibility

and effi ciency into this workfl ow.

Simply advanced

The entire family of SECOM Windows Embedded CE

controls is built on state-of-the-art technology and

provides innovative tools for daily production. RFID

extensions as smart login for a managed machine

use, a clearly structured process visualization and

customized information possibilities for e.g. next

operator call are some important features out of the

portfolio.

Universally applicable solutions

Considering the complexity of yarn, fabric and other

kind of dye machines, the high degree of parallel

processing of SECOM controls provides endless

process possibilities.

The combination with the modular SETEX PLC

concept allows a performance and cost effective

adaptation to all kind of dye machines. Many textile

machinery makers worldwide use these utilities for a

new crop of opportunities.

Intelligent flow

Fabric, machine and product correlations are used

by the integrated formula management to calculate

the optimal dyeing contacts, the best rinsing type,

water temperature and quantity. Using our innovative

functions helps to keep the number of program

steps slim but powerful.

Advanced features as conductivity, article carry over

and critical step lights can easily be added on top of

the standard functionality.

Multilingual

Various languages and fonts can simply be switched

on, e.g. chinese, vietnamese, cyrillic ….

Durable and robust

Development and selection of components based

on characteristics like extended temperature ranges,

rugged environments, unstable power supply and

corrosive conditions.

SECOM ControllerUniversally applicable solutions for tomorrows textile dyeing and finishing

3

SECOM 575

Communicative

The key to success in improving operational

efficiency leads to streamline the workflow. For

continuously optimizing production processes with

minimize risk there’s no way around integration with

OrgaTEX.MES software. All SECOM CE controls

have built in standard Ethernet network functionality.

Effective integration

SECOM controls take care that your automatic dye

kitchens and dosing systems work precisely in sync

with machine calls. The logistics for charge-tanks

and preparation-tanks provides features for “batch

overlapping” dye lot preparation with “look-ahead”

functions.

The entire production data acquisition and collecting,

even values (e.g. pH) entered directly on the controller,

are provided to MES, ERP and “Energy Management”

systems for up-to-the-minute information for immediate

actions.

Safe and protected

Unforeseen incidents as electrical power failure may

happen frequently. The new SECOM controls have

functions for auto-sync, UPS and snapshot recovery.

Instead of downtimes you can proceed with your

production exactly where it stopped right before the

power failure without any loss of data and time.

The front-USB port connects external devices as

backup, barcode and RFID reader.

Professional internet service

The more complex a technology, the more perfect

and flexible its service has to be. SECOM CE controls

provide internet remote access possibilities with

individual customized security gateways and saving

of service-expenses. If desired a 24/7 professional

support availability serves to minimize down-times.

SECOM 848TCE

4

SECOM controller technology for discontinuous processes is designed for a great production experience

through maximum fl exibility and highest industrial suitability.

SECOM 777CE – 777TCE

Companies who expect the unexpected want to preserve some margin in the machine management.

Even very sophisticated automation tasks can be realized without problems. Integrating an automatic

dye kitchen became a standard task.

Complex machines can easily and directly be operated by using the integrated touch screen.

Interaction with process diagrams and manual switches profit from the SECOM 777TCE 10.4" TFT screen.

Users in rough environment might choose the SECOM 777CE model for simultaneously keyboard

and touch operation.

The 777 controller family is the first choice of SETEX’s textile machine manufacturer business partners.

SECOM 777CE

ControllerFor discontinuous processes

5

SECOM 737CE

Projects which prioritize an adequate solution over

an optimal solution will consider a controller with

outstanding technical capabilities and lower priority

to representation.

As successor of SECOM 737XL, the SECOM 737CE

is based on the 777 controller family techniques with

differences in screen size and touch capability. With

the modular Compact PLC concept there are no

limits in customizing the desired configuration.

SECOM 575

The newest offering will expand on the SECOM 5 series

controller family which uses CE technology to support

color display with touch control in a new design.

Plug’n play with predefined standard configurations

for fabric and yarn dyeing machines.

Fitted with a 7" WVGA-TFT display it possesses all

functionalities for a fully automatic dyeing operation.

SECOM X40

The SECOM X40 group controller is the SETEX

solution for specific applications.

The functional upgrades and enhancements to the

SECOM 777 family of controllers allow up to four

PLC connections and therefore up to four dyeing

machines being controlled simultaneously by the

significantly stronger CPU.

Multiple, compact dye machines profit from the

space saving economical concept.

Automatic dye kitchens manage dosing, bucket

conveyer and multiple dissolving units with this

controller.

New innovations as the industrial dyeing machine

that uses supercritical carbon dioxide (CO2) as a

replacement for water can use the SECOM X40

configured to drive one preparation plant with three

dyeing tubes. The information, even when complex,

is displayed clearly and profits from the large 15" TFT

screen display.

Controller for discontinuous processes

(yarn, fabric or other dye machines)

SECOM 575 737CE 777CE 777TCE X40

TFT display 7" 5,7" 8.4" 10.4" 15"

Keyboard – • • – –

Touch control • – • • •

Functionality

Parallel functions 4 12 12 12 12

Maximum no. of functions 50 200 200 200 200

Look ahead/batch overlapping • • • • •

Statistics • • • • •

Integrated formula/time management • • • • •

Short intervention/manual functions • • • • •

User management • • • • •

Production data acquisition (PDA) • • • • •

Internet service portal • • • • •

Multi machine controller – – – – •

Data transfer and backup USB stick USB stick USB stick USB stick USB stick

6

Fabric Seam Detector SD100

Instant sampling and unloading with the fabric

seam at your fingertips

Fabric circulation control

In addition to quickly locating the seam, the precise

SD100 control of fabric circulation in a running

machine is a quality key number.

Smooth mount

The detector is mounted on the outside of fabric

dyeing machines without alignment problems. The

sensor is sewn into the fabric seam and works

independent of fabric speed.

Best available technology

The GMR-techniques with excellent temperature

stability and very strong signals allow environment

temperatures up to 135 °C at todays used high

process speed.

RFID Sensor TR20

Contactless data transfer for user login

Data transparency requires an end-to-end monitoring.

The TR20 RFID sensor integrates a smart user login

to the SECOM CE controller family.

Secure and operator friendly

Unique user tags enable individually-enabled actions

on the controller.

Industrial strength

The installation on a control panel is suitable for

industrial applications with type-IP64 protection. The

reader is plugged in a controller via USB connection.

SETEX SensorsPerformance tools for daily business

Seam Detector SD100

RFID sensor TR20

7

SETEX.OptiWeighFor a controlled weighing workflow: Integrated, precise, reproducible and documented

The SETEX.OptiWeigh solution includes a stand-

alone job ticket and weighing module software, a

SECOM WT2010 controller with weighing terminal

hardware, including two scales and auxiliary equipment.

Free standing compact housing

Free standing ergonomic housing for weighing

equipment and efficiency items. The entire interior

work of the system is designed to provide flexible

choice of components in a color kitchen production

environment.

WT2010

SECOM technology with touch control

The SETEX applications run with robust, silent and

fast industrial flash storage media in a fanless controller.

Synchronized information flow for the entire OptiWeigh

system is provided through accessible connection

of scales, printer and barcode reader via USB and

serial interfaces.

Industrial strength

WT2010 is designed for industrial applications with

type-IP64 protection. To ensure touch control on

the 15" display on a permanent basis the WT2010

provides exchangeable protective foils.

Scales

A standard and economical line of scales is supported

(typically two scales with 3 kg and 32 kg). For both

scale’s supplier (Mettler and A&D) the protocol is

integrated.

SETEX.BatchTool software

The software contains an easy-to-use recipe editor

that manages all production relevant products and

quantities to build the production recipe. The root

data management supplies chemical and dyestuff

administration with comfortable product exchange

functions. The workflow roundup is completed by

the stock management option.

7 reasons pro SETEX.OptiWeigh

• Avoid human errors

• Production-geared routines with tolerance ranges

as a function of quantity

• Repeatability through correlating product quantities

with the job ticket software

• Easy traceability with selectable reports

• Reduce expensive re-dyeing

• Product consumption feedback to stock control

software module

• Best used with SETEX OrgaTEX.MES software

Ergonomic design with rotating and height adjustable housing for

PC and auxiliary equipment

8

Compact PLC

SETEX Compact PLCModular PLC system for an effective customized architecture

The automation of textile dyeing and fi nishing

machines up to highest performance ranges is the

main fi eld of SETEX Compact PLC applications.

Using the modular principle, any machine and

application is made to measure with this fl exible

and future-proof automation solution. The individual

system potential is maximized, existing machinery is

utilized more effi ciently and existing processes are

optimized.

Graphical programming language according to IEC

61131-3 (CoDeSys) and extensive program libraries

allows a fast and clear implementation of given auto-

mation requirements.

A tiny form factor plus fl exible connectivity allow the

superb installation of the Compact racks CR 8 and

CR 16 in any control panel. With 8 or 16 available

slots, small and large process control systems can

easily be realized. If necessary the Compact system

can always be extended via the SETEX own DIOS

bus or via the standardized CAN fi eldbus by using

additional Compact racks and SETEX fi eldbus

modules.

9

CPU boards

CPU Program memory Fieldbus interfaces Programming tool

DIOS (Master) CAN (Master) CoDeSys PLCLAB

CP 8 8 Bit 32K • – – •

CP 14XM 16 Bit 512K – – • –

CP 16XM 16 Bit 512K • • • –

Decentralization boards

Field of application Interfaces

CI 16D Interface module for decentralization DIOS (Slave)

IM ARC PLC - PLC communication Arcnet (RS485)

I/O boards

Digital inputs/outputs Analog inputs/outputs

Inputs Relays Transistor PT100Current/voltage

Counter2 kHz

Counter250 Hz

Counter1 MHz Encoder Current Voltage

AM 008-12 – – – – – – – – – 8 –

AM 060 – – – – 6 1 – – – – –

AM 222 – – – 2 2 1 – – – 2 –

AM 2211 – – – 2 2 1 – – – 1 1

AM 600 – – – 6 – 1 – – – – –

DM 016 – 16 – – – – – – – – –

DM 016-T – – 16 – – – – – – – –

DM 160 16 – – – – – – – – – –

EM2 – – – – – – – 2* 2* – –

* Channel can optionally be used either as counter or as encoder input.

10

FMD 32A plus

The SETEX family of fi eldbus modules provides an extensive selection of compact input/output

modules with digital and analog I/O’s for decentralized automation solutions.

The modules can be used as I/O extensions of the PLC or directly as I/O units for the SECOM controllers.

They are equipped with the SETEX DIOS interface.

Features

• All inputs and outputs are opto-insulated

• LED indication for all inputs and outputs

Fieldbus ModulesRemote I/O’s for flexible connections

Fieldbus Digital inputs/outputs Analog inputs/outputs

DIOS Inputs Relays PT100Current/voltage

Counter2 kHz Current

FMD 8A • 8 8 1 1 1 2

FMD 12A • 12 12 1 1 1 2

FMD 16 • 16 16 – – – –

FMD 16A • 16 16 2 3 2 3

FMD 16A plus • 16 16 3 4 2 4

FMD 24A • 24 24 1 1 1 2

FMD 32 • 32 32 – – – –

FMD 32A • 32 32 2 3 2 3

FMD 32A plus • 32 32 3 4 2 4

11

System Structure

Remote display and terminal operation

Machine with satellite tanks

Machine Dye kitchen

Compact CR16

FMD 16A plus

CT 15

OrgaTEX.MES

SECOM 777CE

Machine

Ethernet

Compact CR16 Compact CR8

SECOM 848TCE

OrgaTEX.MES

Remote terminalRemote terminal

SECOM 646TCE

12

SECOM 848TCE

A particular attention is paid to fi nishing machines because most time and cost intensive treatments

in textile production are already completed upon arriving at the fi nishing process. Quality issues at

the end of the value chain are the most expensive element.

SECOM controller for continuous processes provide online production planning, resource management

and data transparency with the machine control.

Developed and designed for best use with stenter frames, dryers, compactors, weft straighteners

and dye machines, SECOM controllers allow a sustainable production with optimized use of the fi ve

resources material, water, energy, time and workforce.

ControllerFor continuous processes

13

SECOM 646TCE – 848TCE

Innovative function and entire integration

A smart data management includes centralized

production planning and control, data logging during

individual process steps and immediate actions

for resource productivity and energy management

specifications. The SECOM controller 646TCE and

848TCE allow efficient usage and operation by clear

and actionable process visualization.

Complex machines can easily and directly be operated

by using the integrated touch screen. Interaction

with process diagrams and manual switches profit

from the SECOM 848TCE 15" TFT screen.

SECOM controllers for continuous processes allow

to manage specific sensors as SETEX WTM fabric

temperature sensors and SETEX.EH80 exhaust air

humidity sensors as part of a machine system or

control entire finishing machines, but also bridge the

gap to integrate 3rd party machines to the central

OrgaTEX.MES software.

Chemical dosing systems offer a big potential for

savings. SECOM 848TCE in connection with OrgaTEX

provides all required functions for a fully automatic

bath preparation. This method allows low liquor

content, precise volume request and reproducibility

according to the foulard´s dosage and article pickup.

Even very sophisticated automation tasks can be

realized without problems.

Controller for continuous processes

(stenter frames, dryers, compactors, weft straighteners, …)

SECOM 646TCE 848TCE

TFT display 10.4" 15"

Keyboard – –

Touch control • •

Functionality

Statistics • •

Integrated formula/time management • •

Automatic dosing requests • •

User management • •

Production data acquisition (PDA) • •

Internet service portal • •

Data transfer and backup USB stick USB stick

SECOM 646TCE

SECOM 848TCE

14

A SEMATIC solution is composed of SECOM controls with innovative applications, sensors that will make sure that

process quality and efficient resource management is possible and complex networking tasks which profit from

the real-time data transparency.

A particular attention is paid to finishing machines as stenter frames, compactors and foulards, dryers, washing

as well as bleaching machines.

Fabric Width Control

Textile fabric orders are based upon final width,

thread/mesh per cm and weight per m2.

A substantial quality improvement and cost reduction

on new stenter frames and retrofit machines can be

achieved with the combination SETEX Fabric Width

Control and SECOM controller.

The precise width control through “width profiles” is

applied to individually driven spindles and improves

the shrinkage process/width ratio.

Automatic foulard dosage

Chemical dosing systems and automatic foulard

dosage in combination with automated bath analysis

will significantly reduce the volume of pollutant in

your plants effluent.

To prevent the discharge of residual chemical bath

volumes, the system is analyzing the foulard liquor

level during batch processing. The combination foulard/

OrgaTEX.MES software allows immediate article pick

up adjustment. Several parameters as minimum pad

box volume, refill call level and residual quantity allow

low liquor content with precise refill-volume request

and reproducibility, even with batch overlapping.

SEMATICModular process control system for continuous textile machinery automation

15

The display shows the actual temperature profi le

and the preset dwell time.

TheThehheT diddi displsplsplsplayayay shosshshowsws thethe ac actuatual tl tempmpemperaeraeraturturture pe pe profirofirofiroro le le

anand td td the hehe prepreprepresetsetsets dwdw dw dwellellellell tii ti time.me.me.me.

1 HeatSET Control

Precise dwell time control using SECOM controller

and the fabric temperature sensors WTM

Fabrics touch-and-feel and color fastness are just two

parameters depending on precise fabric temperature

control in the drying and thermofixation process.

Also drying, condensation reaction, reactive auxiliaries

(flame retardant finishing or wash-and-wear) – the

key to success for all thermic processes in textile

finishing is the article temperature maintained per

set time.

The combination WTM sensor and SECOM controller

automatically adjusts the fabric speed of a stenter

frame to the optimum (fastest) speed possible whilst

simultaneously applying the required quality values

and energy consumption.

2

3

2 SETEX.EH80

Sensor for exhaust air humidity measurement

Drying and thermofi xation of textile fabric is a very

energy consuming process step. Precise exhaust

control with SETEX.EH80 manages the task to

extract exactly that amount of air humidity needed

to manage a high quality drying process but avoiding

energy waste.

The analyzing unit monitors the sensor as well for

errors and provides an automatic calibration feature.

3 WTM

Sensor for fabric temperature measurement

The fabric temperature sensors WTM V11, V21 and

V40 are designed for the measurement of fabric

temperature in dryers and stenters.

The WTM V11 and V21 contactless measuring units

detect the fabric temperature precisely and with a

high repetitive accuracy. The sensors are resistant

for a wide range of environmental temperature and

installed inside the dryer. The resistance against

contamination is given by an integrated dust guard.

The WTM V40 sensor with its rugged housing is located

outside the dryer cabinet. Owing to measurement

characteristics it can be positioned at a larger distance

to the fabric.

Sensor type Measurement range Ambient temperature

WTM V11 0…250 °C/32…482 °F up to 180 °C/356 °F

WTM V21 0…250 °C/32…482 °F up to 250 °C/482 °F

WTM V40 0…200 °C/32…392 °F up to 250 °C/482 °F

1

16

The scanning system is composed of several CamSCAN heads driven by a SECOM touch screen controller and

a PLC rack.

CamBRIDGE has been developed with focus on providing extremely fast information about weft distortion independent

of color, structure or print pattern of the fabric. Signals to position skew and bow rollers can be provided.

The high resolution CamSCAN CCD matrix cameras deliver a digital picture of the fabric that can be used to

monitor the quality of the measurement.

CamBRIDGE Scanning SystemAutomatic straightening and distortion analysis

Features

• Measurement of woven and knitted fabric

• Precise high fabric speed measurements

(up to 140 m/min)

• Measurement impact compensation of:

dark- and light colored fabric, thread thickness,

fabric technology and speed,

through automatic adjustment of light intensity and

infrared illumination in reflection and transmission

• Fast picture analyses directly on the camera chip

• Visualization of fabric structure and weft angle

Advantages

• Straightening and distortion analysis for 3 to 8 zones

• Option: calculation of weft/mesh density

• Stationary measurements for pre-adjustments

• Maintenance free

• Quality reports

• Distortion monitoring

• Easy adjustments and control even with difficult

fabric technology

Distortion analysis CamBRIDGE

17

CamCOUNT

Automatic monitoring of thread/mesh density

and shrinkage control automation

The CamCOUNT camera system provides a superb

combination of modern technology and smart software

algorithms which results in outstanding measurement

and control of shrinkage and overfeeds. The technology

is based on the CamSCAN system.

Wide fabric range

Measure, analyze and evaluate textile fabric in a

range of 4 to 70 threads per cm (up to 150 threads

with extended option).

Universally applicable solution

The system is used at the inlet and the outlet of stenter

frames, compactors and sanforizing machines to

improve product quality.

Variable set values

The fabric shrinkage and overfeed is automatically

controlled by the set value (%). For specific articles,

customized parameter sets can be pre-configured

and selected via hotkeys.

Fabric Inspector

Monitoring accurately thread and mesh density

The SETEX Fabric Inspector checks incoming

woven or non-woven fabric for thread or mesh

density. In connection with a mobile computer the

design allows a quick and accurate measurement,

visualization and monitoring on site.

The detection optics and algorithms are optimized to

work with static fabric presentation. The results are

fully compatible with SETEX CamCOUNT production

camera systems and stored in OrgaTEX.MES.

The resulting values serve for

• Quality control of incoming textiles

• Acquire default values as manufacturing guidelines

• Article-specific configuration of your shrinkage/

overfeed control system

• Shrinkage/overfeed towards specific fabric weight

(grams per square meter)

Technical advantages

• Fast and simple fabric inspection at various

sections of the production process

• High accuracy in the detection of thread/mesh

density based on digital image processing

• Color neutral evaluation

• Flexible operational area

• Interface to OrgaTEX.MES

The specific application visualizes the fabric image and the

process properties.

Scanning SolutionsFor outstanding fabric finishing

18

Add features to dyeing and finishing machines

Add efficiency to your production process through

anticipated chemical calls with “look ahead”

functions, “batch overlapping”, bath preparation and

online production data acquisition.

Cost management

OrgaTEX.MES in connection with SECOM controls

demon strates the production performance by

machine, batch, article, process and so on. Machine,

batch, alarm and dosing information is transformed

into business information.

Safe and secure

All important production information is stored in the

system. Whether products, production processes or

batch history: the information management is safe to

the company.

Up to date production processes

Use of centralized guided production process

creation for all machines. Add more flexibility with

intelligent treatment parameters, look-up tables

and rules, which interconnect the data for the actual

requirement. Make practical process optimization

through real-time batch analysis.

Everything under control

The permanent online connection to the production

machines allows supervision and control of quality,

times, consumption values, costs and personnel.

OrgaTEX.MES Software Production and performance management software for textile finishing

OrgaTEX.MES

Production machine supervisor or Manufacturing Execution System – OrgaTEX.MES can cover both. The software

suite is composed of scalable modules. Start low and built as you grow to suit continuously the desired level. With

SETEX you have one supplier for MES software and machine control hardware.

Batch scheduler with order interface

19

Entire integration

The information exchange between ERP system,

color laboratory, color kitchen, dyeing and finishing

machines is the vital nerve for any information for

fast-acting strategically decisions.

OrgaTEX.MES solves this with customized solutions

which seamless fit in the master plan.

The detailed real-time fine planning enables an

economic, efficient and versatile production with

high speed and quality.

Online production correction with spectrophotometer

Energy Management

Sustainable production means optimization of

water emission, energy consumption and resource

productivity. With the new energy and utility

management SETEX covers this area with innovative

product variants.

Energy management workflow

The actual energy situation of each involved production

machine is used to calculate the consumption. For

a generic approach on energy management, it is

possible to include the company own power plant,

warm/hot water and water discharge management

to the scenario.

Active actions

Balancing energy load to avoid energy peaks without

influencing the volume and quality of production is

Lab2Bulk

The SETEX Lab2Bulk module integrates the color

laboratory to production in textile dyeing and finishing

mills, providing better processes for maintaining

accuracy, transparency and standards from laboratory

to production.

The interface contains root data import, seam-

less laboratory recipe synchronization with the

corres pon ding OrgaTEX.MES production process

and production correction integration for measurement

supported additions.

Main screen data collection terminal

the target. Power and gas consumption is projected

by trend analyses based on up-to-the-minute infor-

mation of all linked machines. Customized equations

automatize the decision making process.

SETEX Schermuly textile computer GmbH

Hauptstraße 23-25 · 35794 Mengerskirchen · GermanyTel. +49 6476 9147-0 · Fax +49 6476 [email protected] · www.setex-germany.com

13.04.2012 · SD1700701 · INFO-KEA-010-0007-2Technical modifications reserved. All brand and product names are trademarks or registered trademarks of their respective owners. Printed in Germany.

Headquarter

Subsidiaries